Industrial Pretreatment Technology 2006 Pacific Northwest Pretreatment Conference – Sept. 28, 2006...

Industrial Pretreatment Technology

2006 Pacific Northwest Pretreatment Conference –

Sept. 28, 2006

By Stephen G. Edward, PE

For Printed Circuit Board Manufacturing at Merix Corporation

in Forest Grove, Oregon

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Merix Corporation -Industrial Pretreatment Technology

AGENDA

1. Merix Corporation

2. Circuit Board Manufacturing

3. Industrial Wastewater Pretreatment

4. Lessons Learned and Keys to a Successful

Compliance Program

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History• Merix’ Forest Grove facility built in 1982 as the Circuit Board Division

of Tektronix.

• Market changed from captive to merchant providing small to medium volumes of high quality / high tech boards in test, internet server, and communications equipment.

• Spun off into separate entity as Merix Corporation in 1994.

• Started up a new mass lam facility in Wood Village in 2002.

• In 2004, added an ultra-short lead time facility in California.

• In 2005, added five commodity facilities in Asia.


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Merix Corporation Today


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Merix Corporation Today

Merix is a leading manufacturer of technologically advanced, multilayer, rigid printed circuit boards for use in sophisticated electronic equipment. Merix provides quick-turn prototype, pre-production and volume board production to its customers.

Principal markets served by Merix include data communications and wireless telecommunications, automotive, high-end computing, and test and measurement end markets in the electronics industry.


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Printed Circuit Board Manufacturing• Each design custom – Design Review

• Laminate / Prepreg

• Imaging Processes

• Mechanical Processes

• Plating Processes

• Finishing Processes

• Typical Bare Printed Circuit Board Assay


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Printed Circuit Board Manufacturing


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Printed Circuit Board Business Challenges

• Global Competition

• Rapid Evolution of products and processes.

• Typical Oregon Products

– Order Size: 1-20 Panels

– Copper Layers: < 40

– Mixed Dielectrics

– Blind and Buried Vias

– Embedded passives

– Heat Sinks


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Wastewater Characteristics• Heavy Metals (Copper, Nickel, Tin, Lead, Silver, Gold, Manganese)

• Chelators and Complexers

• Acids

• Bases

• Cyanide

• Soluble Photoresist Polymers

• COD / BOD


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Industrial Pretreatment• Effective Technologies

– Neutralization (pH)

– Chemical Precipitation (Metals & Photoresist)

– Clarification (Separation of Metals & Photoresist)

– Ion Exchange (Metals, including gold cyanide complex)

– Reverse Osmosis (Small dissolved solids)

– Ultrafiltration (Polymers)

• For efficiency, Use Appropriate Wastewater Segregation


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Merix – FG Permit Requirements• Daily Flow Proportional Sampling and Analysis for:

– Metals: Ag, Cd, Cr, Cu, Mn, Pb, Ni, Zn.

– Chemical Oxygen Demand.

• Continuous analysis of pH.

• Weekly analysis for CN.

• Semi-annual analysis for Sulfate.

• Periodic analysis for TTO.


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Merix – FG Wastewater Pretreatment Facility


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Industrial Pretreatment Example 1 for Copper

• Wastewater Description:

– [Cu] = 50 mg/L

– Not chelated or complexed

• Treatment Technology:

– Adjust pH to 8.9

– Add polymer and/or flocculant

– Clarify

• Results:

– [Cu] < 0.5 mg/L Complies with Permit Limits


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– [Cu] = 50 mg/L

– Chelated or complexed




– Clarify

• Results:

– [Cu] > 5 mg/L Exceeds Permit Limits


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– [Cu] = 50 mg/L



– Add Ferrous Sulfate or Sulfide Chemistry



– Clarify

• Results:

– [Cu] < 2 mg/L Complies with Permit Limits


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– [Cu] = 50 mg/L



– Pass through Ion Exchange Resin

• Results:

– [Cu] < 0.2 mg/L Complies with Permit Limits


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– [Cu] = 50 mg/L


– Contains Dissolved Photoresist Polymer


– Pass through Ion Exchange Resin

• Results:

– Initial: [Cu] < 0.2 mg/L Complies with Permit Limits

– Later: [Cu] = 50 mg/L Exceeds Permit Limits


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– [Cu] = 50 mg/L, Chelated or complexed

– Contains Dissolved Photoresist Polymer


– Lower pH < 5.5

– Add Ferrous Sulfate or Sulfide Chemistry

– Raise pH to 8.9

– Add polymer and/or flocculant and Clarify

• Results:

– [Cu] < 2 mg/L Complies with Permit Limits


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Industrial Pretreatment Keys• Segregation Strategies

• Unplanned chelation or complexing.

• Unanticipated Photoresist impacts

– Clogging of pumps and filters.

– Coating of probes and other critical control devices.

– Coating of resin.

• Human Beings

– Flexible, but, subject to Errors.


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How Are We Doing?• 2002: Zero Violations.

• 2003: Zero Violations.

• 2004: Three minor Permit Limit exceedances.

• 2005: Zero Violations.

• 2006 to date: One paperwork Violation.


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Plan for Success• Unless there is no chance for an upset, applied IP Technology

should be flexible. Think stable and forgiving!

• Use effective administrative programs: Chemical pre-screening.

• Recruit and Retain quality personnel.

• Continuously improve education of personnel.

• Recognize and reward superior performance.

• Wastewater segregation strategy should anticipate potential upsets and errors.


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Ease of Control & Monitoring


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Ease of Control & Monitoring


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Storage for Segregation & Equalization


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Plan for Success (cont.)• Benchmark to identify unknown options.

– Share environmental successes with competitors and learn from them.

– Enhanced industry performance helps minimize negative public perceptions.

• Institutionalize successful methods.

– Properly implemented, an EMS will enhance compliance systems.

– Merix uses the ISO 14001 International Standard as model for site Environmental Management Systems.


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Summary• Must understand the manufacturing operations and its

requirements.

• Need to understand the limitations of the specific IP Technology in the context of its application.

• Implement Systems that minimize surprises and the opportunity for errors.

• Select and retain the right quality of employees.

• Institutionalize continuous improvement.


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Questions?


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